U.S. patent application number 12/732649 was filed with the patent office on 2011-09-29 for minimally penetrating photovoltaic assembly for use with a sloped roof and related methods.
This patent application is currently assigned to SunPower Corporation. Invention is credited to Michael Knuepfel, Carl J.S. Lenox, Doug Rose.
Application Number | 20110232715 12/732649 |
Document ID | / |
Family ID | 44654961 |
Filed Date | 2011-09-29 |
United States Patent
Application |
20110232715 |
Kind Code |
A1 |
Lenox; Carl J.S. ; et
al. |
September 29, 2011 |
MINIMALLY PENETRATING PHOTOVOLTAIC ASSEMBLY FOR USE WITH A SLOPED
ROOF AND RELATED METHODS
Abstract
An assembly which is lightweight includes an interconnected
array of PV modules, where each PV modules is defined in part by a
module outer perimeter portion. This array is defined in part by an
outer perimeter portion including an upper edge portion, side edge
portions, and a lower edge portion. The array is secured to a
sloped roof along at least one of the upper or lower edge portion
of the array. The assembly further includes interlocking features
along the module outer perimeter portion which distribute uplift
forces to adjacent PV modules. Additionally included is at least
one wind deflector located along the lower edge of the array and
non-penetrating base feet disposed on the sloped roof supporting at
least a portion of the array.
Inventors: |
Lenox; Carl J.S.; (Oakland,
CA) ; Rose; Doug; (San Jose, CA) ; Knuepfel;
Michael; (San Francisco, CA) |
Assignee: |
SunPower Corporation
San Jose
CA
|
Family ID: |
44654961 |
Appl. No.: |
12/732649 |
Filed: |
March 26, 2010 |
Current U.S.
Class: |
136/244 ;
156/71 |
Current CPC
Class: |
Y02B 10/20 20130101;
F24S 2025/6004 20180501; F24S 2025/6007 20180501; F24S 25/67
20180501; Y02B 10/12 20130101; Y02E 10/47 20130101; Y02B 10/10
20130101; Y02E 10/50 20130101; F24S 2025/6001 20180501; F24S 25/20
20180501; H02S 20/23 20141201; F24S 2030/16 20180501; F24S
2025/6008 20180501 |
Class at
Publication: |
136/244 ;
156/71 |
International
Class: |
H01L 31/042 20060101
H01L031/042; B32B 43/00 20060101 B32B043/00; B32B 37/02 20060101
B32B037/02 |
Goverment Interests
GOVERNMENT FUNDING
[0001] The invention described herein was made with government
support under contract number DE-FC36-07GO17043 awarded by the
United States Department of Energy. The United States Government
may have certain rights in the invention.
Claims
1. An assembly comprising: an interconnected array of photovoltaic
(PV) modules, each of the PV modules defined in part by a module
outer perimeter portion, the interconnected array defined in part
by an outer perimeter portion including an upper edge portion, side
edge portions, and a lower edge portion, the interconnected array
configured to be secured to a sloped roof along at least one of the
upper or lower edge portion of the interconnected array;
interlocking features along the module outer perimeter portion
which distribute uplift forces to adjacent PV modules; at least one
wind deflector located along the lower edge portion of the
interconnected array; and one or more non-penetrating base feet
configured to be disposed on the sloped roof, the one or more base
feet supporting at least a portion of the interconnected array of
PV modules.
2. The assembly as recited in claim 1, wherein wind uplift forces
on the interconnected array are resisted through at least one of
distribution of forces within the interconnected array, pressure
equalization treatment, or aerodynamic treatment of the
interconnected array.
3. The assembly as recited in claim 1, wherein the interlocking
features are between adjacent PV modules which planarize adjacent
module edge portions, the interlocking features allowing for a
single PV module to be removed without removal of an adjacent PV
module.
4. The assembly as recited in claim 1, wherein the wind deflector
has a gap between the wind deflector and the lower edge allowing
for air flow between the interconnected array and the roof.
5. The assembly as recited in claim 1, wherein the wind deflector
is a porous wind deflector allowing convective air flow between the
interconnected array and the roof and deflects wind gusts above the
interconnected array.
6. The assembly as recited in claim 1, wherein the interconnected
array, wind deflector, and the base feet are collectively
lightweight such that an average load on the roof does not exceed
about 10 lb/sq feet.
7. The assembly as recited in claim 1, wherein the interconnected
array is configured to be secured to the sloped roof with
penetrating members.
8. The assembly as recited in claim 1, wherein the interconnected
array includes at least a number of the PV modules having a gap
between adjacent PV modules.
9. The assembly as recited in claim 1, wherein the base feet are
non-ballasted base feet.
10. The assembly as recited in claim 1, further comprising
penetrating members coupled with the sloped roof and the
interconnected array, the penetrating members disposed within a
footprint of the interconnected array, along the outer perimeter
portion of the interconnected array, or combinations thereof.
11. The assembly as recited in claim 1, wherein the sloped roof has
a slope greater than 1-in-12.
12. The assembly as recited in claim 1, further comprising at least
one wind deflector located along at least one of the upper edge
portion or the side edge portions.
13. The assembly as recited in claim 1, wherein the one or more
base feet are self-leveling feet.
14. The assembly as recited in claim 13, wherein the one or more
base feet include elastomeric material.
15. The assembly as recited in claim 13, wherein the one or more
base feet are spring feet.
16. The assembly as recited in claim 1, wherein a first side of a
first PV module has a recessed attachment feature, a second side of
a second PV module has a projection attachment feature, and the
projection attachment feature is received within the recessed
attachment feature.
17. The assembly as recited in claim 1, further comprising adhesive
disposed between the base feet and a roof surface.
18. The assembly as recited in claim 1, wherein the one or more
base feet are defined in part by an upper portion and a lower
portion, and a coupler extends from the upper portion.
19. The assembly as recited in claim 1, wherein a first PV module
is rotatably lockable with a second PV module.
20. The assembly as recited in claim 1, wherein a first PV module
is slidably unlockable with a second PV module.
21. The assembly as recited in claim 1, further comprising one or
more penetrating members attached to the roof and forming a roof
attachment location, and at least one flexible tie down connecting
the one or more penetrating members with the interconnected array
at an array attachment location, where the roof attachment location
can be offset from the array attachment location.
22. An assembly comprising: an interconnected array of photovoltaic
(PV) modules, each of the PV modules defined in part by a module
outer perimeter portion, the interconnected array defined in part
by an outer perimeter portion including an upper edge portion and a
lower edge portion, interlocking features along the module outer
perimeter portion, the interconnected array configured to be
coupled with a sloped roof; one or more penetrating members
configured to be coupled with the sloped roof and forming a roof
attachment location; at least one flexible tie down connecting the
one or more penetrating members with the interconnected array at an
array attachment location, where the roof attachment location can
be offset from the array attachment location; and one or more base
feet disposed on the roof, the one or more base feet supporting at
least a portion of the interconnected array of PV modules.
23. The assembly as recited in claim 22, wherein the one or more
penetrating members are coupled with a rafter under a surface of
the sloped roof.
24. The assembly as recited in claim 22, wherein the one or more
penetrating members are offset from the module outer perimeter
portion.
25. The assembly as recited in claim 22, further comprising a tie
down tightening member.
26. The assembly as recited in claim 22, wherein a first PV module
of the interconnected array is rotatably lockable with a second PV
module of the interconnected array.
27. The assembly as recited in claim 22, wherein a first PV module
of the interconnected array is slidably unlockable with a second PV
module of the interconnected array.
28. The assembly as recited in claim 22, wherein the interlocking
features allow for a single PV module to be removed without removal
of an adjacent PV module.
29. A method comprising: mounting two or more photovoltaic (PV)
modules on a sloped roof with minimally- penetrating roof mounting
structure; interconnecting the two or more PV modules into an array
of PV modules; securing at least a portion of an upper edge portion
of the array with the sloped roof; coupling at least one wind
deflector with at least a portion of a lower edge portion of the
array; and resisting wind uplift forces on the array through
distribution of forces within the array, pressure equalization
treatment, and aerodynamic treatment of the array.
30. The method as recited in claim 29, further comprising removing
at least one individual PV module from an array of interconnected
PV modules without removing surrounding PV modules.
31. The method as recited in claim 30, wherein removing the at
least one individual PV module includes sliding a first PV module
relative to a second PV module.
32. The method as recited in claim 29, wherein interconnecting the
PV modules includes inserting a projection attachment feature of a
first PV module into a recessed attachment feature of a second PV
module, rotating the first PV module relative to the second PV
module.
33. The method as recited in claim 29, further comprising
interlocking a first PV module of the array with a second PV module
of the array.
34. The method as recited in claim 29, further comprising disposing
adhesive between the roof mounting structure and a surface of the
sloped roof.
35. The method as recited in claim 29, further comprising securing
a portion of the array to the sloped roof with a flexible tie down
cable, including securing the tie down cable with the array and a
penetrating member coupled with the roof top deck.
36. The method as recited in claim 29, wherein mounting the PV
modules includes disposing the PV modules in a horizontal row of PV
modules, and disposing an interlock between adjacent PV
modules.
37. The method as recited in claim 36, further comprising removing
the interlock and sliding a first PV module relative to the
adjacent PV module.
38. An assembly comprising: an interconnected array of photovoltaic
(PV) modules, each of the PV modules defined in part by a module
outer perimeter portion and having a gap between adjacent PV
modules, the interconnected array defined in part by an outer
perimeter portion including an upper edge portion and a lower edge
portion, the interconnected array secured to a sloped roof along at
least a portion of the upper edge portion of the interconnected
array; interlocking features along the module outer perimeter
portion between adjacent PV modules; at least one wind deflector
located along the lower edge portion of the interconnected array;
and one or more non-penetrating base feet configured to be disposed
on the sloped roof, the one or more base feet supporting at least a
portion of the interconnected array of PV modules.
Description
TECHNICAL FIELD
[0002] The application relates generally to a photovoltaic array.
More particularly, it relates to a minimally penetrating
photovoltaic assembly for use with a sloped roof.
BACKGROUND
[0003] Currently, photovoltaic (PV) modules can be secured to roofs
with rack systems that include vertical stanchions and lateral
rails. In particular, the lateral rails are attached to the
stanchions, which are typically several inches off the roof, and
the PV modules are attached to the rails. Installations of PV
modules using such traditional rack systems may be difficult
because, for example, the installations can be very labor intensive
due to the deficient designs of the stanchions and rails.
Additionally, the stanchions may possibly penetrate deeply into the
roof and/or in a large number of locations. For example, relatively
large holes are often pre-drilled through the roofing material to
accommodate the mounting hardware. Because of the size of these
large holes, and/or the large number of penetrations, it is often
difficult to tell if adequate waterproofing has been achieved. It
should be appreciated that many of these traditional PV rack
systems may often include one or more of the above-described
drawbacks or other drawbacks not mentioned.
SUMMARY
[0004] An assembly includes an interconnected array of photovoltaic
(PV) modules, where each of the PV modules is defined in part by a
module outer perimeter portion. The array is defined in part by an
outer perimeter portion including an upper edge portion, side edge
portions, and a lower edge portion. The interconnected array is
configured to be secured to a sloped roof along at least one of the
upper or lower edge portion of the array. The assembly further
includes interlocking features along the module outer perimeter
portion which distribute uplift forces to adjacent modules.
Additionally included is at least one wind deflector located along
the lower edge of the array and one or more non-penetrating base
feet are configured to be disposed on the sloped roof, where the
base feet supports at least a portion of the interconnected array
of PV modules. Wind uplift forces on the array may be resisted
through distribution of forces within the array, pressure
equalization treatment, and/or aerodynamic treatment of the
array.
[0005] A method includes mounting two or more PV modules on a
sloped roof with non- penetrating roof mounting structure. The two
or more PV modules are interconnected into an array of PV modules
and at least a portion of an upper edge portion of the array is
configured to be secured with the sloped roof. Additionally, at
least one wind deflector is coupled with at least a portion of a
lower edge portion of the array. The method further includes
resisting wind uplift forces on the array through distribution of
forces within the array, pressure equalization treatment, and/or
aerodynamic treatment of the array.
[0006] These and other embodiments, aspects, advantages, and
features will be set forth in part in the description which
follows, and in part will become apparent to those skilled in the
art by reference to the following description of embodiments of the
invention and referenced drawings or by practice of the
embodiments. The aspects, advantages, and features are realized and
attained by means of the instrumentalities, procedures, and
combinations particularly pointed out in the appended claims and
their equivalents.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] Embodiments of the invention may be best understood by
referring to the following description and accompanying drawings
which illustrate such embodiments. In the drawings:
[0008] FIG. 1 illustrates a block diagram of a photovoltaic system
according to one or more embodiments.
[0009] FIG. 2 illustrates a side view of a photovoltaic system
according to one or more embodiments.
[0010] FIG. 3 illustrates a perspective view of a photovoltaic
module assembly according to one or more embodiments.
[0011] FIG. 4 illustrates a perspective view of a photovoltaic
module assembly according to one or more embodiments.
[0012] FIG. 5 illustrates a perspective view of a portion of a
photovoltaic module assembly according to one or more
embodiments.
[0013] FIG. 6 illustrates a perspective view of a portion of a
photovoltaic module assembly according to one or more
embodiments.
[0014] FIG. 7 illustrates a side view of a portion of a
photovoltaic module assembly according to one or more
embodiments.
[0015] FIG. 8 illustrates a side view of a portion of a
photovoltaic module assembly according to one or more
embodiments.
[0016] FIG. 9 illustrates a bottom perspective view of a
photovoltaic module assembly according to one or more
embodiments.
[0017] FIG. 10 illustrates a bottom perspective view of a
photovoltaic module assembly according to one or more
embodiments.
[0018] FIG. 11 illustrates a perspective view of a base foot
according to one or more embodiments.
[0019] FIG. 12 illustrates a bottom perspective view of a
photovoltaic module assembly according to one or more
embodiments.
[0020] FIG. 13 illustrates a bottom perspective view of a
photovoltaic module assembly according to one or more
embodiments.
[0021] FIG. 14 illustrates a bottom perspective view of a
photovoltaic module assembly according to one or more
embodiments.
[0022] FIG. 15 illustrates a top perspective view of a photovoltaic
module assembly according to one or more embodiments.
[0023] FIG. 16 illustrates a top perspective view of a photovoltaic
module assembly according to one or more embodiments.
[0024] FIG. 17 illustrates a top perspective view of a photovoltaic
module assembly according to one or more embodiments.
[0025] FIG. 18 illustrates a top view of a photovoltaic module
assembly according to one or more embodiments.
[0026] FIG. 19 illustrates a side view of a photovoltaic module
assembly according to one or more embodiments.
DESCRIPTION OF THE EMBODIMENTS
[0027] The following detailed description includes references to
the accompanying drawings, which form a part of the detailed
description. The drawings show, by way of illustration, specific
embodiments in which the present photovoltaic assemblies and
methods may be practiced. These embodiments, which are also
referred to herein as "examples," are described in enough detail to
enable those skilled in the art to practice the present
photovoltaic assemblies and methods. The embodiments may be
combined, other embodiments may be utilized or structural or
logical changes may be made without departing from the scope of the
present photovoltaic assemblies and methods. The following detailed
description is, therefore, not to be taken in a limiting sense, and
the scope of the present photovoltaic assemblies and methods is
defined by the appended claims and their legal equivalents.
[0028] In this document, the terms "a" or "an" are used to include
one or more than one, and the term "or" is used to refer to a
nonexclusive "or" unless otherwise indicated. In addition, it is to
be understood that the phraseology or terminology employed herein,
and not otherwise defined, is for the purpose of description only
and not of limitation.
[0029] An assembly includes an interconnected array (or "array") of
photovoltaic (PV) modules, interlocking features, at least one wind
deflector, and one or more non-penetrating base feet. In an option,
the interconnected array, wind deflector, and base feet are
collectively lightweight such that an average load on the roof does
not exceed about 10 lb/sq. feet. For example, an average load of
the lightweight structure is between about 2 lb/sq. feet and about
5 lb/sq. feet. In another example, an average load of the
lightweight structure is about 2.5 lb/sq. feet. As used herein, the
term "about" means that the specified dimension or parameter may be
varied within an acceptable tolerance for a given design or
application. In some embodiments, for example, an acceptable
tolerance for a parameter is .+-.10%. FIG. 1 illustrates an example
of an array 100 of individual PV modules 110. Each of the PV
modules 110 are defined in part by a module outer perimeter portion
112, including an upper edge portion 114, side edge portions 115,
and a lower edge portion 116. The array 100 is defined in part by
an outer perimeter portion 102, an upper edge portion 104, side
edge portions 105, and a lower edge portion 106.
[0030] The array 100 of PV modules 110 are interconnected to one
another with interlocking features 130, as depicted in FIG. 3. The
interlocking features 130 are, in an option, disposed along the
module outer perimeter portion which distributes uplift forces to
adjacent PV modules 110. In an option, the interlocking features
130 are between adjacent PV modules 110 which planarize adjacent
module edge portions. In a further option, the interlocking
features 130 allow for a single PV module 110 to be removed without
removal of an adjacent PV module 110. The array 100 is configured
to be mounted on or secured to a sloped roof 120, for instance as
shown in FIG. 2. The roof can have a slope, for example, of
1-in-12, or greater. In an example, the interconnected array 100 is
coupled with the sloped roof 120 only along less than all edge
portions 104, 105, 106 of the array 100. In an option, the
interconnected array 100 is coupled with the sloped roof 120 only
along at least one or the upper and lower edge portions 104, 106.
In another option, the interconnected array 100 is coupled with the
sloped roof 120 only along the upper edge portion 104. In an
example, the array 100 is coupled with the sloped roof 120 with a
penetrating member that penetrates the sloped roof 120 and is
mechanically coupled with the array 100.
[0031] The array 100 of PV modules 110 may be subjected to wind
uplift forces. In an option, wind uplift forces on the array 100
are resisted in one or more different manners. For instance, a
majority of wind uplift forces may be resisted through distribution
of forces within the array 100, pressure equalization treatment,
and/or aerodynamic treatment of the array 100.
[0032] The distribution of forces within the array 100 includes,
but is not limited to, the mechanical and structural
interconnections between the individual PV modules 110. Pressure
equalization treatment includes methods and/or structure which
equalize pressure between the array 100 and the sloped roof 120 and
above the array 100. For example, the array 100 can include air
gaps between various components so that air can flow through it.
Examples of such gaps include one or more gaps located between the
individual PV modules 110, a perimeter gap located between one or
more PV modules 110 and an outer deflector, and a gap located
between the deflector and the lower edge of the array 100. In
another option, pressure equalization is enhanced by promoting flow
of air under the PV modules 110 while also limiting the volume of
air that can exist in these regions. In a further option, the
deflector is a wind deflector, which may be porous to allow for
convective air flow between the array 100 and the sloped roof 120
and deflecting wind gusts above the array 100.
[0033] The aerodynamic treatment also assists in resisting a
majority of wind uplift forces on the array 100. The aerodynamic
treatment includes, but is not limited to wind deflectors 109, such
as upper wind deflectors, side wind deflectors, or lower wind
deflectors. The wind deflectors can be placed at any relatively
large entry points to an underside of the array 100 to prevent wind
penetration into the entry point. In an option, the wind deflectors
are as tall as the tallest adjacent components in the array 100 to
minimize drag forces on the array 100. In an option, the wind
deflectors are sloped at an angle to reduce drag forces on the
deflector. In a further option, a curb section is utilized to
provide improved aerodynamic performance and aesthetics may also
include compatible features so that the PV modules 110 can lock
into the curb directly, for example either using a rotating or
sliding motion. In a further option, at least one wind deflector is
located along the lower edge of the array 100 so as to minimize
aerodynamic drag and uplift on the array 100.
[0034] Still referring to FIG. 2, one or more non-penetrating base
feet 160 are included and are defined in part by an upper portion
and a lower portion. The base feet 160 can be made from foam, hard
rubber, or other semi-flexible material, and optionally include
features that allow for the PV modules 110 to slide on and off of
the base feet 160. The base feet 160 can include a wide base at the
lower portion with elastomeric material. The material can be
over-molded on to a metal base. Optionally the base feet 160 are
self-leveling feet, for example manually or automatically. For
instance, the base feet 160 are optionally equipped with a height
adjustment, such as a threaded rod, where the base feet 160 would
be spun to adjust the height, even after the PV module 110 is
installed into the array 100. Alternately, a worm drive mechanism
could be provided in which case access would be from the sides.
Finally, the base feet 160 could be equipped with a fixed bearing
on a guide rod to prevent foot rotation, with adjustment provided
by a rotating nut on a rod affixed to the PV module frame, rather
than the base feet 160. In yet another option, the one or more base
feet 160 are spring feet. The spring feet involve supports that
effectively and automatically adjust to inconsistencies in the roof
surface while still providing support to the PV module 110. The
types of springs include, but are not limited to, coil springs,
bellow springs, or leaf springs and are made from a variety of
materials, such as metal or polymers.
[0035] The one or more base feet 160 are configured to be disposed,
for example, in a non-penetrating and/or non-ballasted manner on
the sloped roof 120, and the one or more base feet 160 support at
least a portion of the interconnected array 100 of PV modules 110.
In a further option, the base feet 160 comprise a majority of
supporting structures of the array 100, where the base feet 160
include 50% or greater of the supporting structures of the array
100, not including the sloped roof 120. An adhesive 167 is
optionally disposed between the base feet 160 and a roof surface of
the sloped roof 120. The adhesive 167, such as a temporary
adhesive, would allow for the base feet 160 to be laid out, without
the base feet 160 sliding down the sloped roof 120 or without the
base feet 160 moving when a PV module 110 is slid into place on top
of the base feet 160. Once installed, the adhesive 167 may not be
necessary since the weight of the PV modules 110, anchors on
adjacent PV modules 110, or other locking mechanism would keep the
base feet 160 in position.
[0036] The assembly including the array 100 includes interlocking
features 130, which is depicted in FIG. 3, along the module outer
perimeter portion 112 between adjacent PV modules 110, which
planarize adjacent module edge portions 114, 115, 116. In a further
option, the interlocking features 130 allow for a single PV module
110 to be removed without removal of an adjacent PV module 110.
[0037] In an example, as depicted in FIGS. 1 and 3, a first side
118 of a first PV module 118' has a recessed attachment feature 132
and a second side 119 of a second PV module 119' has a projection
attachment feature 134, and the projection attachment feature 134
is received within the recessed attachment feature 132. The
interlocking features 130 can be used, for example, to lock the
first PV module 118' with the second PV module 119' such as by
rotating the first PV module 118' relative to the second PV module
119', or by rotating the second PV module 119' relative to the
first PV module 118'. To unlock the first PV module 118' from the
second PV module 119', the first PV module 118' is slid relative to
the second PV module 119'.
[0038] In an example as shown in FIGS. 3-6, a side of the PV module
110 features a series of rounded knobs 136. The opposite side of
the PV module 120 has a rounded channel 138, which is complimentary
to the rounded knob 136. Notches 139 cut into the channel 138 allow
the knobs 136 from an adjacent PV module 110 to enter the rounded
channel 138. In one embodiment, sliding the PV module 110 laterally
(along the axis of the channel 138) moves the knobs 136 away from
the notches 139. This lateral motion along the axis prevents the
knobs 136 from becoming detached from the channel 138 of the
adjacent PV module 120. Since the channel 138 and knobs 136 are
concentric and have substantially equal diameters, the PV modules
110 are able to hinge up and down, adjusting to the contours of a
sloped roof 120. As seen in FIG. 6, the side of the PV module 110
which includes the knob 136 has a frame that is substantially flat
or planar. In an option, the side of the PV module 110 which
includes the channel 138 has a frame that includes a chamfer 140.
This limits the hinging motion of two adjacent PV modules 110. At
the rotation limit, the flat frame edge and the chamfered frame
edge butt up against each other. This feature limits the amount the
PV modules 110 can rotate and greatly reduces the bending stress on
the material between the knobs 136 and the frame when the PV
modules 110 are at the rotation limit. The length and frequency of
the knobs 136 can vary. The shorter the lengths of the knobs 136,
the shorter the distance the PV modules 110 need to slide in order
to be installed. For removing a PV module 110 from the middle of an
array 100, limiting the slide distance required also minimizes the
gap required from left to right between module rows, in an option,
the knobs 136 and channels 138 can include a locking mechanism or
tactile "click" that alerts the installer that the PV modules 110
have been slid over the proper amount and are installed
correctly.
[0039] FIGS. 7-8 illustrate another example of an interconnected
array 100 having interlocking features. The features include a
projection attachment feature 134 and a recessed attachment feature
132. The projection attachment feature 134 is disposed within the
recessed attachment feature 132 and the PV modules 110 are rotated
and/or slid into place. To disengage the PV modules 110, one of the
PV modules 110 is slid and an opening between recessed attachment
features 132 and the projection attachment features 134 allow for
disengagement of the projection attachment feature 134 from the
recessed attachment feature 132. In yet another option, a clip can
be used to interconnect the adjacent PV modules 110, where the clip
can be slid into place.
[0040] In an option, a locking tab 135 is further included to
prevent the PV module 110 from rotating back out of position as
well as a bias member 137, such as a molded-in spring feature, to
provide positive engagement in the joint between the adjacent PV
modules 110. These features also provide positive feedback of
proper engagement of the projection attachment feature 134. This
type of feature may also be advantageous because bending down to
engage PV modules 110 on a sloped roof 120 laterally can be
difficult. Thee embodiments uses a more natural motion during
placement that can be done from a standing position, and the
features to help correct slight misalignment.
[0041] FIGS. 9-10 illustrate another example of an interconnected
array 100 of PV modules 110. The interlocking features 130 include
a flange 146 disposed on two adjacent PV modules 110. The flange
146 receives a pin 144 therein which interconnects the two adjacent
PV modules 110. The PV module 110 further includes a cut out 142,
which will further assist in the ability to remove a single PV
module 110 without removal of an adjacent PV module 110. The cut
out 142 is positioned on a first PV module 118' to receive the
flange 146 on a second PV module 119' after the pin 144 is removed,
as shown in FIG. 10. This increases the ability to laterally shift
the PV modules 110 during the removal process, which could be
particularly useful when removing a single PV module 110 from the
middle on an array 100.
[0042] In another option, as shown in FIGS. 11-13, one or more of
the base feet 160 are used to interconnect the PV modules 110
together. For example, the base foot 160 depicted in FIG. 11
includes interlocking features, such as a base coupler 166, which
can extend from an upper portion of the base foot 160. The base
coupler 166 interconnects with a first PV module and a second PV
module (not shown) such that the first and second PV modules are
interconnected via the base coupler 166 of the base foot 160. In an
example, the base coupler 166 includes a lip that extends over a
top portion of the base foot 160. As depicted below in FIGS. 12-13,
the lip engages a flange 170 under adjacent PV modules 110.
[0043] Returning to FIG. 11, a removal member 168 is disposed along
a top portion of the base foot 160, where the removal member 168 is
disposed between adjacent PV modules 110. In an example, the
removal member 168 is a hook or hoop structure that extends upward
from the base foot 160. The removal member 168 can be accessed even
after PV modules 110 have been installed over the base foot 160.
This would allow a broken PV module 110 to be removed from the
center of an array 100 without having to remove adjacent PV modules
110. A repair person could simply use a device such as hooked pole
to pull on the removal member 168 to move the base foot 160 back to
a position where the lip does not engage flange, which would allow
the PV module 110 on top of it to be removed, as shown in FIG. 14.
The device could include a long pole would assist in overcoming the
forces to keep the base foot 160 in place, such as friction and
glue between base foot 160 and a sloped roof 120 in conjunction
with the weight of the PV modules 110 and the weight of a repair
person on top of the supports. After replacing the PV module 110,
the pole and hook could be used to slide the base foot 160 back to
the locked position.
[0044] FIGS. 12 and 13 show an example of how the PV modules 110
are installed. The base feet 160 are placed on the sloped roof 120
at measured intervals. The PV modules 100 are placed on top of the
base feet 160. The PV modules 110 include a cut out 124, allowing
for PV modules 110 to be placed in the base feet 160, as shown in
FIG. 12, and for the lip to be slid over the flange 170 of adjacent
PV modules 110, and locked into place, as shown in FIG. 13. In the
installed position (FIG. 13), the PV module's movement is
restricted in the upward and side-to-side directions. Forward and
aft movement of the base foot 160 can be resisted either through
the weight of the PV modules 110 preventing movement, or a locking
mechanism that engages when the base foot 160 is moved into
position, or a combination thereof. Asphalt shingle and other
roofing materials are often uneven and very high-friction, making
it difficult to slide and adjust PV modules 110 that are placed
directly on top of a sloped roof's surface. This can be a problem
during installation in attempting to make mechanisms line up or
engage with adjacent PV modules 110. Placing the base feet 160
between the sloped roof 120 and the PV module 110 allows a metal to
metal or metal to plastic contact surface (between the bottom of
the PV module 110 and the top of the base feet 160) for the PV
module 110 to easily slide, adjust, and line up with adjacent
module attachment mechanisms.
[0045] To ease installation, the bottom of the base feet 160 could
be coated with a glue or adhesive 167. The adhesive 167 would allow
for the base feet 160 to be laid out, without the base feet 160
sliding down a sloped roof 120 or without the base feet 160 moving
when a PV module 110 is slid into place on top of it. Once
installed, the weight of the PV modules 110, the anchors on
adjacent PV modules 110, or a locking mechanism would keep the base
feet 160 in place. The adhesive 167 would no longer be necessary in
maintaining the structural integrity of the array 100 and therefore
would not need to be weather resistant.
[0046] FIGS. 15-17 illustrate another example of an interconnected
array 100, including various embodiments discussed above and below,
and how the embodiments can be used together to allow a single PV
module 110' to be removed from an interlocking array 100 without
having to remove an adjacent PV module 110''. In the example, PV
module 110' is to be removed from the array 100, for instance in
the event the PV module 110' is damaged. In FIG. 15, the base feet
160 for the PV module 110' and adjacent PV modules 110'' are slid
in the direction shown as 125 to unlock the PV modules 110, 110' to
not restrict movement of the PV modules 110, 110'.
[0047] The PV module 110' is shift in the direction shown as 127,
and a cut out in adjacent PV module 110'' allows the PV module 110'
to be shifted further for removal. As PV module 110' is slid, the
interlocking features, such as the projection attachment features
and recessed attachment features, can be disengaged from one
another. As shown in FIG. 16, an adjacent PV module 110'' is
slightly shifted, or swung upwards away from the sloped roof 120,
and PV module 110' can be removed from the array 100 as further
shown in FIG. 17. The PV module 110' is removed, and can be
replaced with a new PV module 110. To install the new PV module
110, the steps above for removing the PV module 110 are followed,
but in reverse order.
[0048] Referring to FIGS. 18 and 19, an assembly includes an
interconnected array 100 of PV modules 110, each of the PV modules
110 defined in part by a module outer perimeter portion 112. The
interconnected array 100 is interconnected as discussed above. The
interconnected array 100 is coupled with a sloped roof 120. One or
more base feet 160 are disposed in a non-penetrating and
non-ballasted manner on the roof deck, where the one or more base
feet 160 supporting at least a portion of the interconnected array
100 of PV modules 110. In an option, the one or more base feet 160
are disposed along an upper edge portion of the array 100. In one
embodiment, this interconnected array 100 also has interlocking
features such that, for example, the base feet 160 provide support
(or resistance forces) to multiple PV modules 110 that are
interconnected.
[0049] The assembly further includes one or more penetrating
members 180 coupled with the sloped roof 120. The penetrating
members 180 can be placed along a rafter 122 under the roof surface
for increased hold-down form, or attached to the roof decking
independent of rafter location. This allows for positioning of the
penetrating members 180 to be independent of the placement of the
PV modules 110. In a further option, the one or more penetrating
members 180 are offset from the module outer perimeter portion. In
another option, the penetrating members 180 are disposed within a
footprint of the array 100, along the outer perimeter portion of
the array 100, or combinations thereof. In yet another option, the
penetrating members 180 are coupled with the sloped roof 120 and
the array 100, for example with at least one tie down.
[0050] The tie down, such as a flexible tie down, is coupled with
the one or more penetrating members 180, and further with a portion
of the array 100, such as a PV module 110, at an attachment point.
The tie down can go through slots in a frame of the PV module 110,
allowing for attachment, or detachment from the PV module 110. The
tie down can be a cable, wire, conductive or non-conductive
element. An optional tie down tightening member 186 can also be
included. For example, the tie down is pulled though slots and then
into a screw, which when turned takes up the remainder of slack in
the tie down. Since the location of the penetrating members 180 is
independent of the placement of the PV modules 110, the tie down
182 is not necessarily perpendicular relative to the surface of the
sloped roof 120. For instance, in an option, an angle 184 formed
between the tie down 182 and the sloped roof 120 is obtuse.
[0051] The penetrating members 180 may, for example, be placed with
a much larger spacing tolerance than is typical of those used in PV
mounting systems, while still providing uplift resistance needed to
keep the array 100 intact. The embodiments may, for example,
provide a low cost method of attaching some points within an array
100 to the sloped roof 120 to prevent upward wind forces from
lifting PV modules 110 from the sloped roof 120 or overstressing
inter-module connections. By using a flexible tie down, such as a
cable or wire, the resulting force on the joiner is only slightly
higher than that of the upward wind force, but the low-cost
attribute of non-precision alignment of the fixture is
maintained.
[0052] Methods of installing and/or uninstalling the various arrays
100, PV modules 110 and the various embodiments and options
discussed and shown are further discussed herein. The method
includes mounting two or more PV modules 110 on a sloped roof 120
with minimally penetrating and lightweight roof mounting structure.
What is meant by minimally penetrating is that the penetrating
structures are not the primary structures used to hold the array
100 to the sloped roof 120. Other mechanisms, such as pressure
management, or wind uplift management are used to keep the array
100 on the sloped roof 120. The assembly may also be lightweight,
as discussed above. In an option, mounting the PV modules 110
includes disposing the PV modules 110 in a horizontal row of PV
modules 110, and disposing an interlock between adjacent PV modules
110. To remove a PV module 110, the interlock is removed and a
first PV module is slid relative to the adjacent PV module. The
method includes securing at least a portion of an upper edge
portion of the array 100 with the sloped roof 120.
[0053] The method further includes interconnecting the two or more
PV modules 110 into an array 100 of PV modules 110 which planarize
adjacent module edge portions. In an option, interconnecting the PV
modules 110 include inserting a projection attachment feature of a
first PV module into a recessed attachment feature of a second PV
module and rotating the first PV module relative to the second PV
module. The method further optionally includes removing at least
one individual PV module 110 from an array 100 of interconnected PV
modules 110 without removing surrounding PV modules 110. In an
option, removing the at least one individual PV module 110 includes
sliding a first PV module relative to a second PV module.
[0054] Several options for the method are as follows. For instance,
the method includes locking a first PV module relative to a second
PV module, for instance by rotating the first PV module relative to
the second PV module. In a further option, the method includes
disposing adhesive 167 between the roof mounting structure and a
surface of the sloped roof 120, or a height of the roof mounting
structure. In yet another option, the method includes securing the
array 100 to the sloped roof 120 with a tie down, such as a tie
down cable, including securing the tie down cable with the array
100 and a penetrating member coupled with the sloped roof 120.
[0055] The disclosed embodiments discuss various methods of
interconnecting and securing PV modules 110 to sloped roofs 120.
These methods incorporate pressure equalization effects to, for
example, reduce wind loading. The embodiments may also provide a
reduction in the number and penetrations into the sloped roof 120,
and create the ability to remove an individual PV module 110 for
maintenance or replacement without disturbing surrounding PV
modules 110. The embodiments further allow for both portrait and
landscape module orientation. Although developed with sloped roof
applications in mind, many of these concepts are equally applicable
to flat or low-slope roofs.
[0056] References in the specification to "one embodiment", "an
embodiment", "an example embodiment", etc., indicate that the
embodiment described may include a particular feature, structure,
or characteristic, but every embodiment may not necessarily include
the particular feature, structure, or characteristic. Moreover,
such phrases are not necessarily referring to the same embodiment.
Further, when a particular feature, structure, or characteristic is
described in connection with an embodiment, it is submitted that it
is within the knowledge of one skilled in the art to affect such
feature, structure, or characteristic in connection with other
embodiments whether or not explicitly described.
[0057] It is to be understood that the above description is
intended to be illustrative, and not restrictive. For instance, any
of the aforementioned examples may be used individually or with any
of the other examples. Many other embodiments may be apparent to
those of skill in the art upon reviewing the above description. The
scope of the present PV assemblies and methods should, therefore,
be determined with reference to the appended claims, along with the
full scope of legal equivalents to which such claims are entitled.
In the appended claims, the terms "including" and "in which" are
used as the plain-English equivalents of the respective terms
"comprising" and "wherein." Also, in the following claims, the
terms "including" and "comprising" are open-ended, that is, a
system, assembly, article, or process that includes elements in
addition to those listed after such a term in a claim are still
deemed to fall within the scope of such claim.
[0058] The Abstract of the Disclosure is provided to comply with 37
C.F.R. .sctn.1.72(b), requiring an abstract that will allow the
reader to quickly ascertain the nature of the technical disclosure.
It is submitted with the understanding that it will not be used to
interpret or limit the scope or meaning of the claims. In addition,
in the foregoing Detailed Description, various features may be
grouped together to streamline the disclosure. This method of
disclosure is not to be interpreted as reflecting an intention that
the claimed embodiments require more features than are expressly
recited in each claim. Rather, as the following claims reflect,
inventive subject matter may lie in less than all features of a
single disclosed embodiment. Thus, the following claims are hereby
incorporated into the Detailed Description, with each claim
standing on its own as a separate embodiment.
* * * * *